What is Efficiency Monitoring

The performance of equipment in process plants degrades over time, due to factors like fouling, erosion and leakages. Through efficiency monitoring, the performance of the system components and the overall system can be continuously monitored. Performance parameters such as turbine inlet temperature, exhaust flow, fuel flow, bypass flow and pump efficiency are monitored. In this way, timely information on efficiency degradation are provided, which enables a condition-based predictive maintenance programme to be set. Maintenance activities can then be prioritized to minimise efficiency degradation and maximise energy efficiency.

In carrying out efficiency monitoring, the following steps are typically taken:

• Parameters that are measured at site and required for the analysis are identified and included into data collection templates.
• Necessary thermodynamic models are configured to perform heat balance and New & Clean (N&C) calculations using design and commissioning data.
• Regular plant data are analysed.
• Analysis results are discussed with in-house engineers and action plans in terms of maintenance corrections, operational corrections and instrument calibrations are formulated.
• Energy efficiency monitoring methodologies and models are shared with in-house engineers to get their buy-in and where specifically contracted, detailed training is given for them to carry out efficiency monitoring.

Why Efficiency Monitoring?

Continuous efficiency monitoring will make transparent the plant efficiency and the respective component losses. These can be used to drive operational adjustments and an efficiency condition-based predictive maintenance program. The setting of a predictive maintenance program can reduce costs and improve equipment reliability and availability by:

• Lowering the cost of equipment parts and labour as less reactive and preventive maintenance is carried out
• Identifying equipment failures before they occur
• Avoiding unscheduled equipment downtime
• Optimising plant maintenance

What are successful examples of Efficiency Monitoring in process industries?

For instance, Tuas Power Ltd, with the help of Actsys Process Management Consultants Pte Ltd (an accredited ESCO for the process industry), has saved in excess of 1,000,000 MWh over the last 4 years of predictive maintenance program. More details can be found here.

What are the Incentives for Efficiency Monitoring?

Efficiency Monitoring is a form of energy appraisal. Companies that wish to engage an ESCO to conduct efficiency monitoring can apply for the Energy Efficiency Improvement Assistance Scheme (EASe)